End sem presentation 2019 -2020.pptx

1. BITS Pilani
Hyderabad Campus
End Semester Presentation: Second Semester (2019-20)
Department of Mechanical Engineering
Name: G. Praveen Kumar ID No. : 2016PHXF0420H
Supervisor Name : Dr. K. Suresh
DAC members: Dr. Pavan Kumar .P and Dr. Nitin .K

2. BITS Pilani
Hyderabad Campus
Experimental investigations and mathematical
modeling of incremental forming processes

3. BITS Pilani, Hyderabad Campus
• Objectives of the Proposed Research
• Finite element simulations on hole flanging process
• Results and discussions
• Publications
• References
Contents
3

4. BITS Pilani, Hyderabad Campus
1. Analysis of surface roughness in parts formed by incremental forming.
2. Experimental and theoretical studies on formability in incremental forming.
3. Analysis of form accuracy, spring back and forming forces in incremental forming process.
4. Experimental investigation in incremental hole flanging process.
5. Finite element (FE) simulations of incremental forming.
Objectives of the proposed research
4

5. BITS Pilani, Hyderabad Campus
 Hole flanging produced by a single point incremental forming is a new process, in which the sheet with
a pre–cut hole is progressively forced with a tool to produce cylindrical or conical smooth flanges.
 It has various applications in rapid prototyping and low volume production of conical and vertical
flanges in sheet metal parts.
Fig. 1 Schematic representation of incremental hole-flanging process
Introduction to incremental hole flanging process
5

6. BITS Pilani, Hyderabad Campus
Finite element simulation incremental hole flanging process
Fig. 2: Finite element model of incremental hole flanging process
Fig. 3: Time versus Position data for (a) X, (b) Y and (c) Z
ordinate
6

7. BITS Pilani, Hyderabad Campus
 Keyword file for shell element input data
contd…
Finite element simulation incremental hole flanging process
7

8. BITS Pilani, Hyderabad Campus
 Keyword file for material properties input data
contd…
Finite element simulation incremental hole flanging process
8

9. BITS Pilani, Hyderabad Campus
Yield strength (Mpa) 230
Youngs modulus (Gpa) 200
Ultimate strength (Mpa) 320
% Elongation 33
Strength coefficient (Mpa) 519
Strain hardening exponent 0.18
 Table1:Mechanical properties of Deep drawing steel
contd…
Fig. 4 Stress strain diagram
Finite element simulation incremental hole flanging process
9

10. BITS Pilani, Hyderabad Campus
1st stage 2nd stage 3rd stage 4th stage
Fig. 5 Simulations of multistage incremental hole flanging process
10
Finite element simulation incremental hole flanging process
contd…

11. BITS Pilani, Hyderabad Campus
Results anddiscussions
1.Vertical forming forces in IHF
2.Wall thickness distribution
3. Strain path evaluation
11

12. BITS Pilani, Hyderabad Campus
1.Vertical forming forces
Results anddiscussions
Fig. 6: Vertical forming forces vs time
12

13. BITS Pilani, Hyderabad Campus
2.Wall thickness distribution
Results anddiscussions
Fig. 7: Wall thickness profiles of flanges with various stages
13

14. BITS Pilani, Hyderabad Campus
3. Strain path evaluation
Results anddiscussions
Stage 1 Stage 2 Stage 3 Stage 4
Fig. 8: Simulated strain path for different stages
14

15. BITS Pilani, Hyderabad Campus
1. Cui, Z., Gao, L., Studies on hole flanging process using multistage incremental forming. CIRP Journal of Manufacturing Science and Technology,
2010;2:124-128.
2. Petek, A., Kuzman, K., Backward hole-flanging technology using an incremental Approach, Journal of Mechanical Engineering, 2012;58:73-80.
3. Centeno, G., Silva, M.B., Cristino, V.A.M., Vallellano, C., Martins P.A.F., Hole flanging by incremental sheet forming. International Journal of
Machine tool Manufacture,2012; 59: 46-54.
4. Borrego, M., Morales - Palma, D., Martínez-Donaire, A.J., Centeno, G., Vallellano, C., Experimental study of hole-flanging by single-stage
incremental sheet forming. Journal of Materials Processing Technology, 2016;237(1):320-330.
5. Cristino, V.A., Montanari, L., Silva, M.B., Atkins, A.G., Martins P.A.F., Fracture in hole-flanging by single-stage incremental sheet forming.
International Journal of Mechanical Sciences, 2014;83:146-154.
6. Hussain G, Valaei H, Al-Ghamdi KA, Khan B. Finite element and experimental analyses of cylindrical hole flanging in incremental forming.
Transactions of Nonferrous Metals Society of China. 2016;26(9):2419-2425.
7. Surech K, Regalla SP. Effect of time scaling and mass scaling in numerical simulation of incremental forming. InApplied Mechanics and Materials
2014 (Vol. 612, pp. 105-110). Trans Tech Publications.
8. Montanari L, Cristino VA, Silva MB, Martins PA. A new approach for deformation history of material elements in hole-flanging produced by single
point incremental forming. The International Journal of Advanced Manufacturing Technology. 2013 Nov 1;69(5-8):1175-83.
9. Morales-Palma D, Borrego M, Martínez-Donaire A, Centeno G, Vallellano C. Optimization of hole-flanging by single point incremental forming in
two stages. Materials. 2018 Oct;11(10):2029.
10.Martínez-Donaire AJ, Borrego M, Morales-Palma D, Centeno G, Vallellano C. Analysis of the influence of stress triaxiality on formability of hole-
flanging by single-stage SPIF. International Journal of Mechanical Sciences. 2019 Feb 1;151:76-84.
References
15

16. BITS Pilani, Hyderabad Campus
International Journal:
1. Praveen, G., Ram Tarun Reddy, and Kurra Suresh. "Experimental studies on incremental hole flanging
of steel sheets." Advances in Materials and Processing Technologies (2019): 1-11.(Published in Taylor
and Francis) (Scopus)
2. Praveen, G., Inturi Vamsi, Kurra Suresh and Sudha radhika. “Evaluation of surface roughness in
incremental forming using image processing based methods’’Journal of Measurement.(Under review)
International Conference:
1. Suresh, Kurra, Praveen Kumar, Amrita Priyadarshini, and Nitin Kotkunde. "Analysis of formability in
incremental forming processes." Materials Today: Proceedings(2018), 5(9),18905-18910.(Scopus)
2. Praveen, G., and Kurra Suresh “Experimental study on forming force measurement for AA 1100 sheets
by incremental forming” , Materials Today: Proceedings(2019), 18(7),2738-2744.(Scopus)
Publications
16

17. BITS Pilani
Hyderabad Campus
THANKYOU

18. BITS Pilani, Hyderabad Campus
1st stage 2nd stage 3rd stage 4th stage
11
Finite element simulation incremental hole flanging process

19. BITS Pilani, Hyderabad Campus

20. Fig. 2 (a) 1/8 scaled model of a Shinkansen bullet train (b) Ford logo using the F3T
technology

21. Fig. 1 Applications of ISF: a inner side of a hood for Honda S800 model car [8]; b normal feature lines of TOYOTA iQ
compared with sharpen feature line of TOYOTA iQ-GRMN [8]; c customised ankle support [10] d customised
Buddha face (AMINO website); e sample with 4.5-mm-thickness material of hot rolled steel [8]

22. Fig. 3 The manufacture of an ankle support, from request, to scanning of a live subject
(reverse engineering), to setting up a solid model and CAD drawing, to embedding the
shape for toolpath planning, to creating a toolpath for manufacture, to checking for
accuracy

23. Fig. 5 Prototypes for Automotive industries

24. Fig. 6 Non –Automotive Prototype Examples

25. Fig. 8 Shapes used to demonstrate the viability of the process and for experiments

26. Table 2 Potential applications area of AISF